FLOW SWITCHES AND ITS WORKING PRINCIPLE

Table of Contents
 FLOW SWITCHES | What is a Flow Switch?
 What Does Flow Switch work?
o Types of Flow Switch:-
 Paddle or Flapper Type Flow Switch:-
 Diaphragm Type Flow Switch?
 Shuttle Type Flow Switch
 Piston Type Flow Switch:-
 Thermal Flow Switch:-
 Piezoelectric Flow Switch:-

FLOW SWITCHES | what is a Flow Switch?

Flow switches are devices that monitor the flow

through a channel and send a trip signal to various
devices such as Pump.The pump can be indicated by
the flow switch to shut down or turn on. Some of the
general uses are for the protection of the pump,
protection of the cooling circuit and alarms for flow
rates that are too high or too low.A flow switch is
used to monitor the flow of liquids, air or other
gaseous media through a duct, system or loop.These
switches or sensors can be used to monitor flow over
a given period of time, or set up to continuously
monitor total flow.

What Does Flow Switch

work?
To understand how a flow switch works and what it does, it’s helpful
to outline the core components that make up a typical switch. Many
types will include a paddle or magnetic trigger of some sort (the
primary device), which is connected to a circuit and placed in the
channel through which liquid or gas is passing. This paddle is
displaced or rotated by whatever substance is flowing by, and sends a
signal to a secondary component known as the transducer.
The transducer takes this raw signal from the paddle and passes
it on to a transmitter in a readable format. The transmitter, in
turn, measures this reading against a predefined set of
parameters and performs whatever signal or action is required
to adjust the behaviour of components and mechanisms
elsewhere.

In this way, flow switches are able to monitor report and control
the flow rate of liquid or gas through a specific part of a system,
or through the entire system, ensuring flow stays within those
pre-set parameters. If the rate exceeds or drops below what’s
required, it can instantly trigger a series of actions such as
activating an alarm, powering on a pump, diverting flow,
shutting off parts of the system. Which actions a switch performs
will depend entirely on the type of switch and what it’s been
designed for.

Not all flow switches will have a physical paddle as such.

Ultrasonic and other non-intrusive versions are also fairly
commonplace, which work by bouncing a signal back off the
medium being monitored. This is particularly useful in cases
where the medium is contaminated, physically damaging or
otherwise hazardous, or where it’s helpful to have no moving
parts exposed to constant wear and tear.

Types of Flow Switch:-

There are numerous different types of flow switches available.

Paddle or Flapper Type Flow Switch:-

The flow switch consists of a paddle/flapper device hanging with

the flat surface facing the direction of flow through a hinge. A
permanent magnet is connected to this end; a reed contact above
this magnet is located outside the fluid flow.

Diaphragm Type Flow Switch?

In construction, diaphragm type flow switches are similar to

Differential Pressure switches. The only difference is that there is
a gap that allows fluid to flow through the transition between the
inlet and the outlet port, while it is completely closed in
Differential Pressure switches.
Installing these switches allows the inlet port to be on the same
line as the outlet port. The liquid flow usually takes a zigzag
route inside the switch body when this is completed. This effect
results in a significant drop in pressure, which happens when a
liquid flows through the flow switch.

The spindle begins to rise or fall depending on the extent of the

flow due to the movement of DP across the self-created orifice of
the switch housing and the compression spring connected to the
diaphragm assembly via a spindle.

Shuttle Type Flow Switch:-

Shuttle style flow switches operate because of DP or the velocity

of the liquid acting on a disk on the concept of a moving force. As
liquid flow increases to the actuation setting, a magnet-
equipped shuttle is displaced.
When displaced by fluid flow, this shuttle actuates a hermetically
sealed, SPDT or SPST reed switch within the unit stem. A
compression spring or gravity provides shuttle return when flow
decreases.

Piston Type Flow Switch:-

A piston flow switch, encapsulating a permanent magnet, is

positioned in the flow path within the unit housing. When
displaced by the pressure differential from fluid flow, this piston
magnetically actuates a hermetically sealed reed switch (SPST or
SPDT, depending on the series) within the unit.
The piston metering land diameter precisely sets the actuation
point by regulating bypass clearance. A stainless steel spring
provides positive piston return as flow decreases. The reed
switch, when actuated, can be used to operate remote alarms or
indicators. Or, it may be integrated into automatic system
controls.
Thermal Flow Switch:-
There are many applications where knowing whether there is flow or a no-
flow condition of a fluid in a pipe is important. A thermal flow switch is an
option to consider providing such positive indication of flow or no-flow
conditions. a thermal flow switch operates without any moving parts and
therefore is more reliable.

A thermal flow switch, also known as a thermal dispersion flow switch, is a

precise flow sensing device. The principle sensing method is that of heat
diffusion. “The operation of thermal dispersion flow sensing is attributed to
L.V. King who, in 1914, published his famous King’s Law revealing how a
heated wire immersed in a fluid flow measures the mass velocity at a point
in the flow. King called his instrument a “hot-wire anemometer”. However,
it was not until the 1960s and 1970s that industrial-grade thermal dispersion
devices finally emerged.”
A typical thermal flow switch consists of two temperature sensors. One
sensor measures the temperature of the fluid when the sensor probe is
immersed in the liquid. The other temperature sensor is heated by a
constant power. This creates a temperature difference between the two
sensors. According flow switch gives an output.

Piezoelectric Flow Switch:-

Piezoelectricity is the charge created across certain materials

when a mechanical stress is applied.

Piezoelectric flow switch exploit this effect by measuring the

voltage across a piezoelectric element generated by the applied
force or pressure. They are very robust and are used in a wide
range of industrial applications.

When a force is applied to a piezoelectric material, an electric

charge is generated across the faces of the crystal. This can be
measured as a voltage proportional to the pressure.
A given static force results in a corresponding charge across the
sensor, by using electronic circuit we can generate a digital
output at set flow.

Gas flow switches are designed to measure the velocity of gases,

including air and vapors. These devices may function as standalone
sensors or as part of a sensor system with integrated displays. A key
parameter for these switches is the flow rate, which is determined by a
rotating vane within the device. As gas flows through, the vane rotates and,
upon reaching a certain speed, triggers contacts to close an electrical
circuit. These switches are commonly utilized in HVAC (Heating,
Ventilation, and Air Conditioning) systems, although their technology can
vary significantly.
 Flow
Switch Circuit Diagram
The circuit diagram for a flow switch is shown below. This circuit
controls the flow of fluids within a system. A flow switch can be
installed within a pipe, where it activates in response to the movement
of liquid or air against a paddle component. The switch will either open
or close a set of electrical connections linked to relays, indicator lights,
or motor starters. Usually, the switch features both normally open
(NO) and normally closed (NC) electrical contacts.
As depicted in the circuit diagram above, the motor will activate when
coil "M" is energized, causing the switch contact to close in response
to adequate liquid or air flow. This setup employs a single-phase
circuit with a flow switch, ensuring the motor turns on with liquid flow
and stops when flow ceases. Overcurrent protection for the motor is
provided by overload heaters in this configuration.
 Below is a comparison between a flow switch and a tamper switch.

 A flow indication is another name for the flow switch, while the
supervisory switch is another name for the tamper switch.
 A flow switch's primary job is to identify and keep track of the flow rate
of process media like liquids, gases, and steam, while a tamper
switch's primary job is to determine whether or not a sprinkler valve
has been completely closed.
 The weight of the flow switch is 569 grams, while the weight of the
tamper switch is 2 lbs.
 A flow switch can be built using a hinged or spring-mounted paddle,
while this tamper switch can be built using an actuator, often a lever or
cable with a resting position.

Advantages and Disadvantages of Flow Switches
Here are several benefits of utilizing a flow switch:

 These switches are incredibly reliable tools for calculating flow rates.
 These switches provide precision, adaptability, and affordability.
 They are accurate.
Here are some disadvantages of using a flow switch:

 Gas inclusions may cause errors.

 Flow switches provide decreased conductivity.
 Costly upkeep is necessary after installation.
 It is susceptible to rust caused by liquids with a water base.
 It has an intricate design.
 Stability is poor.
 Low-density fluids are impossible to quantify.

Applications of Flow Switches

Below are some examples of applications for flow switches:

 The basic function of these switches is to measure flow rates.

 These switches are essential for detecting fluid flow and measuring
fan speed.
 This switch prevents the central heating system's heating element
from being boosted before the blower's airflow has been detected.
 These switches can be used for drain line flow monitoring, safety
spray nozzle monitoring, oil well system testing, pump protection, and
relief valve monitoring.
 These switches are primarily utilized for fluid flow rate monitoring and
control in an industrial process system.
 These switches are employed in pump staging, pump or valve failure,
flow protection, and flow or blockage detection.
 These switches are typically utilized in reservoirs and tank storage
systems to keep the tanks at the desired level.
 In big & commercial buildings, huge flow switches are employed for
HVAC systems.


Chapter 4: How are flow switches installed?

Flow switches are commonly installed within industrial piping systems
and typically feature two ports on either side, with shapes ranging
from cylindrical to rectangular. These ports facilitate straightforward
installation into the piping network. To identify which liquid has
reached its destination when two different liquids are present at the
system's ends, the ports should be connected to separate pipes
carrying each liquid. Due to the differing viscosities of the liquids, an
electrical current will flow through one port but not the other, based on
the thickness of the fluids. This variation in viscosity allows for the
detection of the first fluid, enabling the switch to turn on or off
depending on whether the arrival of both fluids was anticipated.

Types of Fluids Flow Switches Detect

A flow switch is capable of detecting a range of liquids, including both
clear liquids like water and opaque or turbid liquids.

The primary consideration for utilizing a flow switch involves

understanding its interaction with various applications. These switches
monitor the flow within a conduit and provide a signal to activate or
control system components such as pumps. Key factors to consider
when selecting a flow switch include the type of media being
monitored, the diameter of the pipe, the temperature range, and the
operating pressure. Flow switches find applications in diverse
systems, including blending or additive processes, duct-based
heating, and air supply systems.

Flow Switch Specifications

Key considerations for operation and performance include:

Material Used: It's important to select a flow switch based on the type
of media it will encounter. For water systems, materials like brass and
bronze are commonly chosen due to their resistance to corrosion,
rust, and wear. Plastic is an option when the media won’t experience
freezing or extreme temperatures, as it is lightweight and resistant to
rust.

Pipe Diameter: The diameter of the pipe is crucial for selecting a flow
switch, as the switch must fit appropriately over the pipe's size.
Accurate measurement ensures proper functionality and installation.

Operating Pressure: Consider the maximum head pressure that the

device can endure from the media. This factor influences the choice of
material for the flow switch.

Media Temperature Range: The temperature range indicates the

highest temperature the media can reach. This is usually determined
by the construction and lining materials of the switch.

Flow Rate: The flow rate, which can vary, is a critical specification
because it directly affects the switch’s activation. Ensure this is
appropriately matched to the switch's capability.

Mass Flow Rate: The mass flow rate refers to the amount of material
passing through a specific area per unit of time. The following
formulas can be used to calculate the mass flow rate:
For flat, plane surfaces:

Where:

ρ = mass density of the fluid

v = velocity field of the mass elements flowing

A = cross-sectional vector area/surface

Q = volumetric flow rate

m = mass flux

For curved areas:

Velocity Flow Rate: The "velocity flow rate" measures how far a fluid
moves laterally through a system in a given unit of time. This can be
calculated using the equation below. Unlike calculating the fluid's
velocity at a particular point, the velocity flow rate provides a broader
measure of the fluid's movement. This measure is straightforward to
assess and is especially useful for liquids due to their constant
density.

For curved areas, "velocity flow" describes the rate at which a fluid
moves laterally through a system. To calculate this, use the equation
provided below. Instead of measuring the fluid's velocity at a single
point, the velocity flow rate assesses the movement of the fluid
throughout the entire system. This measurement is easy to obtain and
is particularly useful for liquids due to their consistent density.

Volumetric Flow Rate: This measures the volume of gas or liquid

passing through a fixed point in a system within a specific time frame.
The equation below is used to determine the volumetric flow rate. This
measurement is particularly advantageous for gas systems.

Physical and Electrical Flow Switch Specifications

When choosing flow switches, physical criteria must be considered, as
there are various mounting and end-fitting options available.

Mounting Types
Mounting options for flow switches are designed for integration with
the process line. They include inline flow meters, compression fittings,
and flanges. Inline-mounted flow switches generally require a straight
pipe section for installation.

In-Line Flow Switch Diagram

Insertion mounts are placed parallel to the flow direction, often
requiring additional access methods, such as a threaded hole in the
process pipe.

Non-Invasive: Non-invasive flow switches can be used in closed pipe

systems without needing direct installation in the flow path.

End Fittings
Clamp: Devices are clamped between two existing process pipes and
installed parallel to the flow channel. External attachment flow meters
are non-intrusive and can be used in closed piping systems without
direct mounting in the flow path. Doppler or ultrasonic flow meters
often use this type of mounting to measure flow through the pipe.

Compression Fittings: Compression fittings use a sleeve or ferrule to

secure a junction and prevent leaks.

Flanged: Devices are fitted between two existing flanged sections of

process pipes, usually aligned parallel to the flow direction. The
connection is made using circular or square flanges, typically secured
by bolting or welding.

Plain End: Devices come with a straight, plain pipe end designed to fit
into the bell end of the connecting pipe.

Socket Weld / Union: This end fitting, which may include a weld neck,
is intended for welding or soldering.
Threaded: Devices are screwed into two existing process pipes and
positioned parallel to the flow channel. The most common thread type
used is the National Pipe Thread (NPT).

Flow Switches Output Options

Flow switches can generate signals that are transmitted over long
distances using analog current levels (transmitters), such as those
ranging from 4 to 20 mA. The output circuit carries a current
proportional to the measurement, ensuring accurate transmission
despite line noise and resistance through feedback.
Analog Voltage: Outputs based on analog voltage measurements are typically
straightforward linear functions.

Frequency: Outputs can use frequency modulation (FM), amplitude modulation

(AM), sine waves, or pulse trains, where frequency or its variations are involved.

Switch: The output involves a switch or relay that changes state. For instance, a
flow switch will activate or deactivate when the process reaches a set threshold,
maintaining the proper operation of the system.

Switch Specifications
Switch specifications include:

Mechanical contacts in electro-mechanical flow switches often use

relays and reed switches.

Solid-state switches, which have no moving parts, utilize electronic

components. The main types are Field Effect Transistors (FETs) and
PIN diodes. FET switches create a channel for current to flow from the
FET's drain to the source. PIN diodes consist of a highly doped
positive (P) material sandwiched between a negative (N) material and
a very resistive intrinsic layer.

Normal State Options:

Normally Open (NO) switches do not allow current to flow when open.
They require contact to be made to activate.

Normally Closed (NC) switches allow current to pass when in their

default state and require breaking contact (opening) to operate.

Required Number of Poles and Throws: Some manufacturers offer

custom switches with varying poles and throws for specific needs. The
number of poles denotes how many separate circuits can be
controlled simultaneously, while the number of throws indicates how
many circuits each pole can manage. This setup is reflected in the
switch’s NO/NC configuration, with breaks (interrupts) being
introduced into each circuit as the switch operates.

Flow Switches with extra functionality

There are flow switches with extra functionality available, such as:

Audible or Visual Alarms

Instruments have visible or auditory alerts to warn users of hazardous

conditions.

Averaging / Multi-Insertion

Multi-insertion flow meters measure the flow rate at various places

along the flow stream to estimate the flow rate.

Controller Functions

Devices that have or take sensor input-output a control signal. These

controls may include limits, PID, logic, etc.

Programmable Meters

Usually, programmable meters have a microprocessor within them.

Electronic adjustments can be made for various materials, ranges,
outputs, etc.

Recorder / Totalizer Functions

The amount of the controlled material, media, or process variable is

totaled by totalizer functions. For example, a data logger that records
system or process variables and controls commands for subsequent
viewing or analysis performs a recorder function. There may also be a
chart recorder that may plot (chart) flow history or provide total flow for
a specified period.

Sanitary

Devices are made for usage in hygienic settings, like those found in
the medical and food processing industries.
Suspended Solids / Slurries

Devices are capable of handling fluids with suspended particles

(slurries). Usually, the meter technology selected affects what kinds of
materials are used.